High wear resilient soft yarn

ABSTRACT

Various implementations include a method of forming a bulked continuous filament (BCF) yarn. The method includes providing N molten streams of polymer, providing M spinnerets, and spinning the N molten streams of polymer through the M spinnerets. At least a first group of filaments and a second group of filaments are spun through the M spinnerets. The first group of filaments each have a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different. The method further includes combining the filaments from the M spinnerets together and texturizing the spun filaments.

BACKGROUND

Filaments having a low denier per filament are soft but are more prone to breaking. Filaments having a higher denier per filament are more durable, but they are not as soft as filaments having a lower denier per filament. Thus, there is a need in the art for a yarn that provides durability with softness.

BRIEF SUMMARY

According to a first aspect, a method of forming a bulked continuous filament (BCF) yarn comprises: (1) providing N molten streams of polymer, wherein N is an integer and is greater than or equal to 1; (2) providing M spinnerets, wherein M is an integer and is greater than or equal to one; (3) spinning the N molten streams of polymer through the M spinnerets, wherein at least a first group of filaments and a second group of filaments are spun through the M spinnerets, the first group of filaments each having a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different; (4) combining the filaments from the M spinnerets together; and (5) texturizing the spun filaments.

In some implementations, the method further includes winding the BCF yarn after the spun filaments are texturized.

In some implementations, spinning the N molten streams of polymer through M spinnerets consists of spinning a first group of the plurality of filaments having a first average denier per filament and a second group of the plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different.

In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 10% along the lengths of the filaments.

In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments.

In some implementations, each filament in the first group of filaments and the second group of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments.

In some implementations, the first average denier per filament is greater than the second average denier per filament.

In some implementations, the average denier per filament of the first group of filaments is at least 1.5 times larger than the average denier per filament of the second group of filaments.

In some implementations, the first group of filaments are between 2% and 33% of a total number of filaments of the BCF yarn.

In some implementations, a total number of filaments of the BCF yarn is between 50 and 400.

In some implementations, the N molten streams of polymer are extruded from one extruder.

In some implementations, a radial cross-sectional shape of each of the filaments in the first group is the same as a radial cross-sectional shape of each of the filaments in the second group.

In some implementations, a radial cross-sectional shape of each of the filaments in the first group is different from a radial cross-sectional shape of each of the filaments in the second group.

In some implementations, the N molten streams of polymer includes a single polymer.

In some implementations, M equals one, and the spinneret defines a first set of openings having a first diameter and a second set of openings having a second diameter, wherein the first diameter and the second diameter are different.

In some implementations, M is greater than one, and wherein a first spinneret defines a set of openings have a first diameter, and a second spinneret defines a set of openings having a second diameter, wherein the first diameter and the second diameter are different.

In some implementations, the spun filaments are randomly texturized.

According to a second aspect, a bulked continuous filament (BCF) yarn comprises a plurality of filaments, each filament having an average denier along its length, the plurality of filaments comprising a first group of a plurality of filaments having a first average denier per filament, and a second group of a plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different.

In some implementations, the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament.

In some implementations, the first average denier per filament and the second average denier per filament vary less than 10% along the lengths of the filaments.

In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments.

In some implementations, the plurality of filaments comprising the first group of the plurality of filaments and the plurality of filaments comprising the second group of the plurality of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments.

In some implementations, the first average denier per filament is greater than the second average denier per filament.

In some implementations, the first average denier per filament is at least 1.5 times larger than the second average denier per filament.

In some implementations, the first group of filaments are between 2% and 33% of a total number of filaments of the BCF yarn.

In some implementations, a total number of filaments of the BCF yarn is between 50 and 400.

In some implementations, the filaments have the same radial cross-sectional shape.

In some implementations, the first group of the plurality of filaments has a first radial cross-sectional shape, and the second group of the plurality of filaments has a second radial cross-sectional shape, wherein the first and the second radial cross-sectional shapes are different.

In some implementations, all of the filaments are spun from one molten polymer stream.

In a third aspect, a carpet has a pile formed from a BCF yarn, and the BCF yarn comprises a plurality of filaments, wherein each filament has an average denier along its length, the plurality of filaments comprising a first group of a plurality of filaments having a first average denier per filament, and a second group of a plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different.

In some implementations, the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament.

In some implementations, the first average denier per filament and the second average denier per filament vary less than 10% along the lengths of the filaments.

In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments.

In some implementations, the plurality of filaments comprising the first group of the plurality of filaments and the plurality of filaments comprising the second group of the plurality of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments.

In some implementations, the first average denier per filament is greater than the second average denier per filament.

In some implementations, the first average denier per filament is at least 1.5 times larger than the second average denier per filament.

In some implementations, the first group of filaments are between 2% and 33% of a total number of filaments of the BCF yarn.

In some implementations, a total number of filaments of the BCF yarn is between 50 and 400.

In some implementations, the filaments have the same radial cross-sectional shape.

In some implementations, the first group of the plurality of filaments has a first radial cross-sectional shape, and the second group of the plurality of filaments has a second radial cross-sectional shape, wherein the first and the second radial cross-sectional shapes are different.

In some implementations, all of the filaments are spun from one molten polymer stream.

BRIEF DESCRIPTION OF DRAWINGS

Example features and implementations are disclosed in the accompanying drawings. However, the present disclosure is not limited to the precise arrangements and instrumentalities shown. Similar elements in different implementations are designated using the same reference numerals.

FIG. 1 is schematic diagram of a system for producing bulked continuous filament (BCF) yarn, in accordance with one implementation.

FIG. 2 is a cross-sectional view of the filaments of a BCF yarn.

FIG. 3 is schematic diagram of a system for producing BCF yarn, in accordance with another implementation.

FIG. 4 is schematic diagram of a system for producing BCF yarn, in accordance with another implementation.

FIG. 5 is a schematic diagram of a texturizer according to one implementation.

FIG. 6A is a side view of BCF yarn that has been produced by the system of FIG. 1 .

FIG. 6B is a side view of yarn produced by the traditional false twist method of the prior art.

FIG. 7 shows BCF yarn produced by the system of FIG. 1 as tufted pile in a carpet according to one implementation.

FIG. 8 shows a filament from the first group of filaments and a filament from the second group of filaments having a wavelike axial cross-sectional shape, according to one implementation.

DETAILED DESCRIPTION

According to a first aspect, a method of forming a bulked continuous filament (BCF) yarn comprises: (1) providing N molten streams of polymer, wherein N is an integer and is greater than or equal to 1; (2) providing M spinnerets, wherein M is an integer and is greater than or equal to one; (3) spinning the N molten streams of polymer through the M spinnerets, wherein at least a first group of filaments and a second group of filaments are spun through the M spinnerets, the first group of filaments each having a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different; (4) combining the filaments from the M spinnerets together; and (5) texturizing the spun filaments. In some implementations, the filaments are texturized randomly.

According to a second aspect, a BCF yarn including a plurality of filaments is provided. Each filament has an average denier along its length. The plurality of filaments includes a first group of a plurality of filaments having a first average denier per filament and a second group of a plurality of filaments having a second average denier per filament. The first average denier per filament and the second average denier per filament are different. Clearly such BCF yarn may be obtained, but is not necessarily obtained, through the method of forming a BCF yarn of the first aspect. Nevertheless, the BCF yarn of the second aspect may show various preferred features similar or equal to the features obtained through the method of the first aspect.

According to a third aspect, a carpet, rug, or carpet tile (collectively referred to herein as “carpet”) comprising the yarn obtained through the first aspect and/or in accordance with the second aspect is provided. Herein this may relate to a flooring product with a tufted or woven pile.

FIGS. 1, 3, and 4 show various implementations of systems for forming bulked continuous filament (BCF) yarn. Each system includes at least one extruder, at least one pump, a spin pack including at least one spinneret, and a texturizer. The BCF yarn produced by the systems and methods disclosed herein are texturized in three dimensions and can be produced at a higher speed than traditional false twist methods. In some implementations, the yarn is randomly texturized. The BCF yarn produced by the disclosed systems and methods produces a yarn with filaments that are differently bulked than with the traditional false twist method. For comparison, FIG. 6A shows a side view of BCF yarn that has been produced by the methods disclosed herein, and FIG. 6B shows a side view of yarn produced by the traditional false twist method. The resulting BCF yarn exhibits a softer and more durable yarn than yarn produced by the traditional false twist method.

FIG. 1 shows a system 100 including one extruder 110, one pump 120, a spin pack 140 including one spinneret 152, and a texturizer 180. The extruder 110 provides a molten stream of polymer 190 to the pump 120. The pump 120 has a pump inlet 122 and a pump outlet 124. The pump inlet 122 is in fluid communication with the extruder 110, and the pump outlet 124 is in communication with the spinneret 152 of the spin pack 140. The pump 120 creates a pressure differential across the pump inlet 122 and the pump outlet 124 to cause the molten stream of polymer 190 to flow from the extruder 110, through a plurality of openings 162, 164 defined by the spinneret 152 of the spin pack 140. As the molten stream of polymer 190 flows out of the plurality of openings 162, 164 defined by the spinneret 152, the molten stream of polymer 190 is spun into a plurality of filaments 172, 174. The filaments 172, 174 are then quenched by a quencher 170 and combined and texturized by the texturizer 180, forming the BCF yarn 199. The system 100 in FIG. 1 produces the yarn 199 (extrusion, drawing, and texturing) continuously, but in other implementations, the yarn may be extruded and taken up in one step and is then later unwound, drawn, and textured in another step, or extruded, drawn, and textured in one or more operations.

The molten stream of polymer 190 can include any thermoplastic polymer material, for example, polyamide (PA) such as PA6, PA6.6, PA6.10, polyether sulfone (PES) such as PTT, polybutylene terephthalate (PBT), polyethylene terephthalate (PET) or recycled PET, polyolefin (PO) such as polyethylene (PE), or polypropylene (PP).

The spinneret 152 shown in FIG. 1 defines a first set of openings 162 and a second set of openings 164. The first set of openings 162 are sized to produce a first group of filaments 172 having a first average denier per filament along a length of the filaments, and the second set of openings 164 are sized to produce a second group of filaments 174 having a second average denier per filament along a length of the filaments. FIG. 2 shows a cross-section of the filaments 172, 174 spun by the spinneret 152 that comprise the BCF yarn 199 shown in FIG. 1 . As seen in FIG. 2 , filaments spun through the first set of openings 162 have a first average denier per filament, and the first average denier per filament is greater than the second average denier per filament of filaments spun through the second set of openings 164. However, in other implementations, the first average denier per filament is less than the second average denier per filament. In some implementations, the spinneret defines more than two groups of openings, and each set of openings produces a group of filaments having an average denier per filament that is different than the average denier per filament for the group(s) of filaments produced by the other set(s) of openings.

The first set of openings 162 defined by the spinneret 152 are shaped such that the first group of filaments 172 exiting the first set of openings 162 have a first radial cross-sectional shape, and the second set of openings 164 defined by the spinneret 152 are shaped such that the second group of filaments 174 exiting the second set of openings 164 have a second radial cross-sectional shape. The first group of filaments 172 and second group of filaments 174 produced by the first set of openings 162 and second set of openings 164, respectively, produce the same cross-sectional shape, as shown in FIG. 2 . The radial cross-sectional shape shown in FIG. 2 is trilobal, but the radial cross-sectional shape in other implementations may be circular, oval, fox, or other suitable radial cross-sectional shape. And, in other implementations, the first group of filaments and second group of filaments produced by the first set of openings and second set of openings, respectively, produce different radial cross-sectional shapes. In addition, the filaments may be solid or define at least one hollow void.

The spun filaments 172, 174 are then combined to form a BCF yarn 199 and are texturized by the texturizer 180 to texturize the BCF yarn 199. Texturizing may result in the length of the filament shrinking by 3-25%, for example. Other aspects measuring the extent to which the filaments are texturized include crimping, total recovery, bulking, and shrinkage. The texturizer 180, which is shown in FIG. 5 , includes a slotted tube 182, a plurality of jets 188, and a heat source 192. The slotted tube 182 defines an inner surface 184, and a plurality of fins 186 extending radially inward from the inner surface 184. The plurality of jets 188 introduces air jets that cause the filaments 172, 174 to flow through the slotted tube 182. The size of the slotted tube 182 and the fins 186 extending from the inner surface 184 of the slotted tube 182 form a sufficiently narrow passage such that the filaments 172, 174 do not pass straight through the slotted tube 182, but are, e.g., randomly, texturized within the slotted tube 182 due to the pushing of the filaments 172, 174 by the plurality of jets 188 upstream of the slotted tube 182. As the filaments 172, 174 are forced through the slotted tube 182 by the air jets created by the plurality of jets 188, the filaments 172, 174 are heated by the heat source 192. The heat and the dynamics of the filaments 172, 174 passing through the slotted tube 182 texturize the resulting BCF yarn 199, causing it to shrink in length. The number of fins 186 extending from the inner surface 184 of the slotted tube 182 can be varied to change the ratio of surface area to volume of the slotted tube 182. An increase in the ratio of surface area to volume of the slotted tube 182 increases the amount of surface area with which the filaments 172, 174 come in contact, which affects the overall appearance of the texturized yarn 199. The heat source 192 shown in FIG. 5 is a heater that creates hot air, but in other implementations, the heat source is a steam generator. After the spun filaments 172, 174 have been texturized, the BCF yarn 199 is wound. Thus, the filaments 172, 174 are processed in a single stage, which increases the speed of manufacturing and creates a softer yarn. In contrast, two stage manufacturing for yarns includes a first stage of extruding, finishing, and spooling the filaments then a second stage of drawing, texturing, and winding the filaments.

FIG. 3 shows another implementation of a system 300 including one extruder 310, three pumps 320 a, 320 b, 320 c, a spin pack 340 including three spinnerets 352, 354, 356, and a texturizer 380. The extruder 310 provides a molten stream of polymer 390 to each of the three pumps 320 a, 320 b, 320 c. The pumps 320 a, 320 b, 320 c each have a pump inlet 322 and a pump outlet 324. The pump inlet 322 of each pump 320 a, 320 b, 320 c is in communication with the extruder 310, and the pump outlet 324 each pump 320 a, 320 b, 320 c is in communication with one of the three spinnerets 352, 354, 356 of the spin pack 340. The pumps 320 a, 320 b, 320 c create a pressure differential across the pump inlets 322 and the pump outlets 324 to cause the molten stream of polymer 390 to flow from the extruder 310, through a plurality of openings 362, 364, 366 defined by the spinnerets 352, 354, 356 of the spin pack 340. As the molten stream of polymer 390 flows out of the plurality of openings 362, 364, 366 defined by the spinnerets 352, 354, 356, the molten stream of polymer 390 is spun into a plurality of filaments 372, 374, 376. The filaments 372, 374, 376 spun from each of the three spinnerets 352, 354, 356 are then combined and texturized by the texturizer 380 to texturize the resulting BCF yarn 399. Because the system 300 shown in FIG. 3 includes three pumps 320 a, 320 b, 320 c, the output of each of the pumps 320 a, 320 b, 320 c to each of the spinnerets 352, 354, 356 in the spin pack 340 can be adjusted as necessary to change the denier of the filaments 372, 374, 376 that are output by the spinnerets 352, 354, 356.

The molten stream of polymer 390 can include any thermoplastic polymer material, for example, polyamide (PA) such as PA6, PA6.6, PA6.10, polyether sulfone (PES) such as PTT, polybutylene terephthalate (PBT), polyethylene terephthalate (PET) or recycled PET, polyolefin (PO) such as polyethylene (PE), or polypropylene (PP).

The spin pack 340 shown in FIG. 3 includes a first spinneret 352, a second spinneret 354, and a third spinneret 356. The first spinneret 352 defines a first set of openings 362, the second spinneret 354 defines a second set of openings 364, and the third spinneret 356 defines a third set of openings 366. The first set of openings 362 are sized to produce a first group of filaments 372 having a first average denier per filament along a length of the filaments, the second set of openings 364 are sized to produce a second group of filaments 374 having a second average denier per filament along a length of the filaments, and the third set of openings 366 are sized to produce a third group of filaments 376 having a third average denier per filament along a length of the filaments. The first average denier per filament produced by the first set of openings 362 is greater than the second average denier per filament produced by the second set of openings 364, and the second average denier per filament produced by the second set of openings 364 is greater than the third average denier per filament produced by the third set of openings 366. However, in other implementations, the first average denier per filament, second average denier per filament, and third average denier per filament are different sizes in relation to each other. In other implementations, the first average denier per filament, second average denier per filament, or third average denier per filament is different from one of the other average deniers per filament, but two of the average deniers per filament can be the same. In some implementations, the spinnerets define more than one set of openings, and each set of openings produces a group of filaments having an average denier per filament that is different than the group of filaments produced by any other set of openings.

The first set of openings 362 defined by the first spinneret 352 are shaped such that the first group of filaments 372 exiting the first set of openings 362 have a first radial cross-sectional shape, the second set of openings 364 defined by the second spinneret 354 are shaped such that the second group of filaments 374 exiting the second set of openings 364 have a second radial cross-sectional shape, and the third set of openings 366 defined by the third spinneret 356 are shaped such that the third group of filaments 376 exiting the third set of openings 366 have a third radial cross-sectional shape. The first group of filaments 372, second group of filaments 374, and third group of filaments 376 spun through the first set of openings 362, second set of openings 364, and third set of openings 366, respectively, produce the same cross-sectional shape. However, in other implementations, the first group of filaments, second group of filaments, and third group of filaments have different cross-sectional shapes.

The filaments 372, 374, 376 spun by each of the spinnerets 352, 354, 356 are then combined to form a BCF yarn 399 and are texturized by the texturizer 180 shown in FIG. 5 . After the spun filaments 372, 374, 376 have been texturized, the BCF yarn 399 is wound. Thus, the filaments 372, 374, 376 are processed in a single stage, which increases the speed of manufacturing and creates a softer yarn. In contrast, two stage manufacturing for yarns includes a first stage of extruding, finishing, and spooling the filaments then a second stage of drawing, texturing, and winding the filaments.

FIG. 4 shows another implementation of a system 400 including three extruders 410 a, 410 b, 410 c, three pumps 420 a, 420 b, 420 c, a spin pack 440 including three spinnerets 452, 454, 456, and a texturizer 480. Each of the three extruders 410 a, 410 b, 410 c provide a molten stream of polymer 490 a, 490 b, 490 c to one of the three pumps 420 a, 420 b, 420 c. The pumps 420 a, 420 b, 420 c each have a pump inlet 422 and a pump outlet 424. The pump inlet 422 of each pump 420 a, 420 b, 420 c is in communication with one of the extruders 410 a, 410 b, 410 c, and the pump outlet 424 of each pump 420 a, 420 b, 420 c is in communication with one of the three spinnerets 452,454, 456 of the spin pack 440. The pumps 420 a, 420 b, 420 c create a pressure differential across the pump inlets 422 and the pump outlets 424 to cause the molten stream of polymer 490 a, 490 b, 490 c to flow from each of the extruders 410 a, 410 b, 410 c, through a plurality of openings 462, 464, 466 defined by the spinnerets 452, 454, 456 of the spin pack 440. As the molten stream of polymer 490 a, 490 b, 490 c flows out of the plurality of openings 462, 464, 466 defined by the spinnerets 452, 454, 456, the molten stream of polymer 490 a, 490 b, 490 c is spun into a plurality of filaments 472, 474, 476. The filaments 472, 474, 476 from each of the three spinnerets 452, 454, 456 are then combined and texturized by the texturizer 480. Each of the three extruders 410 a, 410 b, 410 c can contain a molten stream of a different polymer 490 a, 490 b, 490 c than, or the same polymer as, any of the other extruders 410 a, 410 b, 410 c. Because the system 400 shown in FIG. 4 includes three pumps 420 a, 420 b, 420 c, the pressure provided by each of the pumps 420 a, 420 b, 420 c to each of the spinnerets 452, 454, 456 in the spin pack 440 can be adjusted to as necessary to cause an even flowrate of the molten stream of polymer 490 a, 490 b, 490 c through spinnerets 452, 454, 456, and thus, an even flowrate of filaments 472, 474, 476.

The molten stream of polymer 490 a, 490 b, 490 c can include any thermoplastic polymer material, for example, polyamide (PA) such as PA6, PA6.6, PA6.10, polyether sulfone (PES) such as PTT, polybutylene terephthalate (PBT), polyethylene terephthalate (PET) or recycled PET, polyolefin (PO) such as polyethylene (PE), or polypropylene (PP).

The spin pack 440 shown in FIG. 4 includes a first spinneret 452, a second spinneret 454, and a third spinneret 456. The first spinneret 452 defines a first set of openings 462, the second spinneret 454 defines a second set of openings 464, and the third spinneret 456 defines a third set of openings 466. The first set of openings 462 are sized to produce a first group of filaments 472 having a first average denier per filament along a length of the filaments, the second set of openings 464 are sized to produce a second group of filaments 474 having a second average denier per filament along a length of the filaments, and the third set of openings 466 are sized to produce a third group of filaments 476 having a third average denier per filament along a length of the filaments. The first average denier per filament produced by the first set of openings 462 is greater than the second average denier per filament produced by the second set of openings 464, and the second average denier per filament produced by the second set of openings 464 is greater than the third denier per filament produced by the third set of openings 466. However, in some implementations, the first average denier per filament, second average denier per filament, and third denier per filament are different sizes in relation to each other. In other implementations, the first average denier per filament, second average denier per filament, or third denier per filament is different from one of the other average deniers per filament, but two of the average deniers per filament can be the same. In some implementations, the spinnerets define more than one set of openings, and each set of openings produces a group of filaments having a denier per filament that is different than the group of filaments produced by any other set of openings.

The first set of openings 462 defined by the first spinneret 452 are shaped such that the first group of filaments 472 exiting the first set of openings 462 have a first radial cross-sectional shape, the second set of openings 464 defined by the second spinneret 454 are shaped such that the second group of filaments 474 exiting the second set of openings 464 have a second radial cross-sectional shape, and the third set of openings 466 defined by the third spinneret 456 are shaped such that the third group of filaments 476 exiting the third set of openings 466 have a third radial cross-sectional shape. The first group of filaments 472, second group of filaments 474, and third group of filaments 476 produced by the first set of openings 462, second set of openings 464, and third set of openings 466, respectively, produce the same cross-sectional shape. However, in other implementations, the first group of filaments, second group of filaments, and third group of filaments produced by the first set of openings, second set of openings, and third set of openings, respectively, produce different cross-sectional shapes.

The filaments 472, 474, 476 spun by each of the spinnerets 452, 454, 456 are then combined to form a BCF yarn 499 and are texturized by the texturizer 180 shown in FIG. 5 . After the spun filaments 472, 474, 476 have been texturized, the BCF yarn 499 is wound. Thus, the filaments 472, 474, 476 are processed in a single stage, which increases the speed of manufacturing and creates a softer yarn. In contrast, two stage manufacturing for yarns includes a first stage of extruding, finishing, and spooling the filaments then a second stage of drawing, texturing, and winding the filaments.

The implementations of systems shown in FIGS. 1, 3, and 4 include different numbers of extruders, pumps, and spinnerets. In other implementations, the system can include any number of extruders producing N molten streams of polymer and M spinnerets, where N is an integer and is greater than or equal to 1 and M is an integer and is greater than or equal to one. In some implementations, the N molten streams of polymer are extruded from one extruder, but in other implementations, the N molten streams of polymer are extruded from a plurality of extruders. The N molten streams of polymer can include a single polymer or different polymers. The N molten streams of polymer are spun through the M spinnerets to form groups of filaments. The filaments produced by the M spinnerets are combined together and, e.g., randomly, texturized to form a BCF yarn.

In some implementations, M equals one. The one spinneret defines a first set of openings having a first diameter and a second set of openings having a second diameter that is different than the first diameter. In some implementations, M is greater than one. A first spinneret defines a set of openings that have a first diameter, a second spinneret defines a set of openings that have a second diameter that is different than the first diameter.

The M spinnerets spin at least a first group of filaments and a second group of filaments. The first group of filaments each have a first average denier per filament along a length of the filaments, and the second group of filaments each have a second average denier per filament along a length of the filaments. The first and second average denier per filament are different. In some implementations, the first average denier per filament is greater than the second average denier per filament. The radial cross-sectional shape of each of the filaments in the first group can be the same as or different than a radial cross-sectional shape of each of the filaments in the second group.

Clearly, the BCF yarn obtained through the method of the first aspect described in the figures also shows the features of the second and third aspects.

In some implementations of the first, second, and/or third aspects, the total number of filaments of the BCF yarn is between 50 and 400, and the first group of filaments, which have a larger denier per filament than one or more other groups of filaments, are between 2% and 33% of a total number of filaments of the BCF yarn. In some implementations, the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament. In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 10% along the lengths of the filaments. In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 5% along the lengths of the filaments.

It is not excluded that the first and/or the second group would include less than 2% of the filaments of the yarn, or even as few as only 1 filament. For example, in some implementations, the BCF yarn obtained through the first, second, and/or third aspect contains a plurality of, e.g., up to 50 or 100, groups of filaments of all different denier per filament.

In some implementations, the difference in DPF between the respective groups of filaments is such that the filaments of the first group along their length always have a denier value that is smaller, or larger as the case may be, than the denier the filaments of the second group have along their length. In other words, the filaments of the first group, at any radial cross-section, are thicker/thinner, than any segment along the length of the filaments of the second group. As aforestated, in some implementations, the DPF of each filament is constant along its length and/or varies less than 10% or less than 5% along its length.

In some implementations of the first, second, and/or the third aspect, each filament in the first group of filaments and/or the second group of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments. Wavelike refers to a change in the DPF of the filament in different segments along the length of the filament. For example, one segment along the length of the filament may have a DPF that is larger than the DPF of another segment along the length of the filament. The change in DPF for each filament may vary between 10% and 40%, for example. As shown in FIG. 8 , filament 172′ from the first group of filaments has a first segment 178 that has a higher DPF than a second segment 179 that is axially spaced from and axially adjacent the first segment 178. And, filament 174′ from the second group of filaments has a first segment 176 that has a higher DPF than a second segment 177 that is axially spaced from the first segment 176. The segment of filament 172′ with the smallest DPF (e.g., segment 179 shown in FIG. 8 ) has a higher DPF than the DPF of the segment of filament 174′ with the largest DPF (e.g., segment 176).

In some implementations of the first, second, and/or the third aspect, the average denier per filament of the first group of filaments is at least 1.5 times larger than the average denier per filament of the second group of filaments.

The BCF yarn is texturized such that the overall length of the yarn is reduced by between 3% and 25%, depending on the processing speeds, conditions, and desired output of the yarn. For example, a higher percentage of reduction in length yields a bulkier yarn. The amount of texturizing is measured by using ASTM D4031-01, which includes heating the BCF yarn and measuring an increase in tension or an increase in linear density of the BCF yarn in response to the heating. The heating of the BCF yarn can be performed with an oven or with a designated measurement tool, such as a textured yarn tester (TYT).

In some implementations of the first, second, and/or the third aspect, the distribution of the filaments of the first and second group in the cross-section of the yarn is such that they are equally, or at least more or less equally, distributed, for example such that the inner 50% area of the yarn contains not more than 1.25 times (100/G) % filaments of a group, where G is the number of groups of filaments having different denier. Thus, filaments of the first and second group are present at the outer surface of the yarn, as well as in the center of the yarn. The more or less equal distribution leads to a softer feeling of the yarn and the carpet containing the yarn.

FIG. 7 shows BCF yarn 799 manufactured by the systems and methods disclosed herein included as the tufted pile 794 in a carpet 796. The BCF yarn 799 includes a first group of filaments 772 and a second group of filaments 774, and each filament 772, 774 has an average denier along its length. The first group of filaments 772 has a first average denier per filament, and the second group of filaments 774 has a second average denier per filament. The first average denier per filament is larger than the second average denier per filament. The filaments in the first group of filaments 772 and the filaments in the second group of filaments 774 shown in FIG. 7 have the same radial cross-sectional shape. However, in other implementations, the first group of filaments has a first radial cross-sectional shape, and the second group of filaments has a second radial cross-sectional shape that is different than the first cross-sectional shape. All of the filaments 772, 774 shown in FIG. 7 are spun from one molten polymer stream, but in other implementations, the filaments are spun from two or more molten polymer streams.

In some implementations of the first, second, and/or the third aspect, the total number of filaments of the BCF yarn is between 50 and 400, and the first group of filaments, which have a larger denier per filament than one or more other groups of filaments, are between 2% and 33% of a total number of filaments of the BCF yarn. In some implementations, the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament. In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 10% along the lengths of the filaments. In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 5% along the lengths of the filaments. In some implementations, such as described above in relation to FIG. 8 , each filament in the first group of filaments and the second group of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments. In some implementations, the average denier per filament of the first group of filaments is at least 1.5 times larger than the average denier per filament of the second group of filaments.

A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claims. Accordingly, other implementations are within the scope of the following claims.

Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present claims. In the drawings, the same reference numbers are employed for designating the same elements throughout the several figures. A number of examples are provided, nevertheless, it will be understood that various modifications can be made without departing from the spirit and scope of the disclosure herein. As used in the specification, and in the appended claims, the singular forms “a,” “an,” “the” include plural referents unless the context clearly dictates otherwise. The term “comprising” and variations thereof as used herein is used synonymously with the term “including” and variations thereof and are open, non-limiting terms. Although the terms “comprising” and “including” have been used herein to describe various implementations, the terms “consisting essentially of” and “consisting of” can be used in place of “comprising” and “including” to provide for more specific implementations and are also disclosed. As used herein, when a value is given as “between” a first and second number, the range includes the first and second numbers. 

1. A method of forming a bulked continuous filament (BCF) yarn comprising: providing N molten streams of polymer, wherein N is an integer and is greater than or equal to 1; providing M spinnerets, wherein M is an integer and is greater than or equal to one; spinning the N molten streams of polymer through the M spinnerets, wherein at least a first group of filaments and a second group of filaments are spun through the M spinnerets, the first group of filaments each having a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different; combining the filaments from the M spinnerets together; and texturizing the spun filaments.
 2. The method of claim 1, further comprising winding the BCF yarn after the spun filaments are texturized.
 3. The method of claim 2, wherein spinning the N molten streams of polymer through M spinnerets consists of spinning a first group of the plurality of filaments having a first average denier per filament and a second group of the plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different.
 4. The method of claim 3, wherein the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 10% along the lengths of the filaments.
 5. The method of claim 4, wherein the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments.
 6. The method of claim 5, wherein each filament in the first group of filaments and the second group of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments.
 7. The method of claim 6, wherein the first average denier per filament is greater than the second average denier per filament. 8.-17. (canceled)
 18. A bulked continuous filament (BCF) yarn comprising a plurality of filaments, each filament having an average denier along its length, the plurality of filaments comprising a first group of a plurality of filaments having a first average denier per filament, and a second group of a plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different.
 19. The BCF yarn of claim 18, wherein the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament.
 20. The BCF yarn of claim 19, wherein the first average denier per filament and the second average denier per filament vary less than 10% along the lengths of the filaments.
 21. The BCF yarn of claim 20, wherein the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments.
 22. The BCF yarn of claim 21, wherein the plurality of filaments comprising the first group of the plurality of filaments and the plurality of filaments comprising the second group of the plurality of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments.
 23. The BCF yarn of claim 22, wherein the first average denier per filament is greater than the second average denier per filament.
 24. The BCF yarn of claim 23, wherein the first average denier per filament is at least 1.5 times larger than the second average denier per filament.
 25. The BCF yarn of claim 24, wherein the first group of filaments are between 2% and 33% of a total number of filaments of the BCF yarn.
 26. (canceled)
 27. The BCF yarn of claim 25, wherein the filaments have the same radial cross-sectional shape.
 28. The BCF yarn of claim 25, wherein the first group of the plurality of filaments has a first radial cross-sectional shape, and the second group of the plurality of filaments has a second radial cross-sectional shape, wherein the first and the second radial cross-sectional shapes are different.
 29. (canceled)
 30. A carpet having a pile formed from a BCF yarn, the BCF yarn comprising a plurality of filaments, each filament having an average denier along its length, the plurality of filaments comprising a first group of a plurality of filaments having a first average denier per filament, and a second group of a plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different.
 31. The carpet of claim 30, wherein the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament.
 32. The carpet of claim 31, wherein the first average denier per filament and the second average denier per filament vary less than 10% along the lengths of the filaments.
 33. The carpet of claim 32, wherein the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments. 34.-73. (canceled) 